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Dr Zainab IdrisAdvanced Oleochemical Technology Division
MPOB
CONFERENCE on NEW BUSSINESS OPPORTUNITIES in OLEOCH EMICALS, BIOMASS & NUTRACEUTICALS SECTOR
(Jointly Organized by MPOB & POIC Sabah Sdn Bhd)
1st March 2011
Name : Zainab binti IdrisSpecialization : Fatty nitrogen based surfactants, surfactants,
fabric softener,
Higher education: 1988 B. Sc. (Chemistry) –Laurentian University, Ontario,Canada. 1998 M. Sc. (Organic Chemistry)-Universiti Putra Malaysia. 2010 Ph. D (Chemistry) - Universiti
Kebangsaan Malaysia
Working Experience :1989-1990 Assistant Chemist, Rubberex Sdn.Bhd. (IGB),1990-1991 Chemist, Rubberthread Sdn Bhd.(IGB), Jan 1992- Sept 1992 Attachment Research Officer, PORIM1992-2000 Research Officer, PORIM (now known as MPOB)
Current Senior Research Officer (MPOB)Group Leader of Specialty Chemical Group Head of Process Engineering and Design Unit of MPOB
� Introduction� Palm Oil and Oleochemicals� Functions of basic oleochemicals� Functions of intermediates/ derivatives� Application in personal care and consumer
products� Opportunities for new business avenue
Palm Oil and Oleochemicals
� Government effort to increase GNI to RM 47 Billion by 2020� 12 industry sectors were identified and Palm oil
industry is 2nd
� 8 Entry Point Projects (EPP) identified for Palm Oil Industry� Oleo and Derivatives – EPP No 6� Increase GNI to RM 5.8 Billion by 2020
� Key stakeholders: MPOB, MPOC, Private sectors, MIDA
� Shift focus of production from basic oleo-chemicals to higher value oleo-derivatives
� Focus development of 4 key products i) Agro chemicals ii) Surfactants iii) Bio lubricantsiv) Bio Polyols v) Glycerol derivatives.
� Capture part of global demand of USD 215 Billion by 2020, given easy access to feedstock
02468
10
2002 2003 2004 2005 2006 2007
CA
GR
(%)
Demand Capacity
CAGR (’02-’07): 5.1% CAGR (’09-’14): 4.6%
0%
10%
20%
30%
Basics
Surfactants
Biopol yol
Bi o-lub.
Agroch
em.
…suffers from low margins and overcapacity…
…and 98% of Malaysia’s production is focused on basic oleos
� Promote local oleo-derivative industry/players�Pilot plants - JV with SMEs�R&D efforts on identif ied high value products�Focused global market research support
� Incentivize end-users to set up factories in Malaysia�Integration w ith local derivatives producers�Removing bureaucratic hurdles of setting-up business
� Exploit synergies w ith petro-chemical players�Sharing of raw materials for oleo-derivatives
� Support local players to set up plant/JV abroad�Support to local players through networks, market know ledge, collaboration with investors/technology providers
MESOCARP (CPO): Fatty acid composition equivalent to tallow
KERNEL(CPKO): Fatty acid composition equivalent to coconut
MesocarpKernel
Chemicals derived from plant and animal
CH2
HC
CH2 OCOR3
OCOR2
OCOR1
3 H2O
CH2
HC
CH2 OH
OH
OH R1COOH
R2COOH
R3COOH
Triglyceride Water Glycerol Fatty acids
R1, R2 and R3 vary in chain length and unsaturation
� Fatty acids, � Methyl esters (FAME), � Fatty alcohols, � Fatty amines and� Glycerols
Oleochemicals derivatives : Activation of the functional group on basic
oleochemicals
CR
O
OX if X=H, fatty acidif X=CH3, methyl ester
H3C Funtional group
2 commom functional group on basic oleochemicals
CR Y
H
H
if Y= OH, fatty alcoholif Y= NH2, fatty amines
where R is hydrocarbon moiety
General basic oleochemical structure
HO OHOH
Back bone of triglyceride: Gly cerol
� Alcohol ethoxylates, � Alcohol sulfates, � Alcohol ether sulfates, � Quaternary ammonium salts� Monoacylglycerols (MAG), � Diacylglycerols (DAG), � Structured triacylglycerols (TAG), � Sugar esters
Plant based and Animal Based• Even numbered carbon chain
Petroleum based• Branched and odd numbered carbon chain.• Fatty alcohols and fatty amines
Differences or absence of one characteristic in either one of the resources create an
opportunity for synergism between both resources
� Incorporation of a small portion of oleo based intermediates in petroleum based products� Oil well stimulating agent: performed and
degrade.� Oil field recovery� In polyurethane formulation� Stick formulation� Candle formulation� Industrial textile
Price of crude oil Price of crude oil rose rose in the late 1970s in the late 1970s
manufacturers switched manufacturers switched from petrochemicals tofrom petrochemicals tooleochemicalsoleochemicals
The “Bad Prions”
� Production Capacity: 2.6 million ton/year� Export capacity: 2.17 million tonne in 2009� Export value: RM6.56 billion in 2009� Major markets:
� EU � China� USA� Japan
Application of basic and intermediates in Personal care and Consumer products
• Basic oleochemicals: Hydrocarbon/oil phase
• Intermediates: Surface active properties
• Water soluble ingredients
SURFACTANTS
Palm fruits
Palm Kernel (CPKO)
Mesocarp oil (CPO)
Olein
s tearin
Fatty acids , glycerol, methyl es ters , fatty alcohol and fatty amines
Surfactants
Finished productsPackaging industryRetailers , consumer
� Direct use and as intermediate for surfactants � Trendy-Branding� Population-target market� Competitiveness-how fast it change with
demand and trend� Environmental concern� Economics of production-raw material, labour,
logistic, transportation
Waxy body to formulated productsCreamyStickEmmoliency/ lubricating/ protection
� What are these chemicals?� Why very useful?� Surface coating industry?� Delivery of cosmetic ingredients? Why we need
delivery?� Performance enhancer?
Amphiphilic compound used to mix oil and water in one emulsion system
Hydrophillic head(water loving)
Lypophillic tail (oil loving)
Functions:o Cleansing agento Emulsifying agento Foam boosterso Hydrotropeso Solubilizing agento Suspending
agent
Types/classification :o ANIONICS - soap, fatty
alcohol sul fate, fatty alcohol ether sulphate
o NON-IONICS - fatty acid ethoxylate, fatty alcohol ethoxylate
o CA TIONICS - esterquatso AMPHOTE RICS - betaines
ANIONICS :
MES for laundry detergent, liquid cleaner, etc.
CATIONICS : Esterquat for Household fabric softerner
A class of anionic surfactants derived from neutralization of fatty acid or
saponification of triglycerides
Palm oil : Palm kernel oil80:20, 75:20, 70:30 & 60:40
� mois ture 9-12.5%
� Total Fatty Matter 79-83%
� Free fatty acid 1.3 - 7.0%
� Glycerine 0.4 -0.6%
� Sesq. Present
� Titre 38-52oC
1. AMALGAMATOR2. ROLL MILL3. PLODDER4. PNEUMATIC PRESS MOULD
1 2 3
4
� Specialty soaps - contain special additives for specific functionality (1- 5%)
� Process similar to toilet soaps� Additives:
� Emollients, humectant,
� Moisturisers, occlusive agents, dermabrasive agents, medicaments, anti-irritants, etc.
Trendy Palm-based soap noodles to replace tallowProcess - neutralization of fatty acidsPlus other additives to enhance transparency, appearance and performancesCan be used for decoration and skin care or gifts
41
Item RM/year
A. Capital Investment:• Machinery & Equipment• Renovation• Vehicles • etc
RM 556,500
B. Operational Cost• Raw material• Labor• Utilities• Rental • Packaging• etc.
RM 704,700
Production Capacity: 150,000 kg/yr
Sales and Revenue
COST BENEFIT ANALYSIS
Internal Rate of Return (IRR) 33.08
Benefit : Cost RM 1.12
Net Present Value @ 12% RM 488,383
Return of Investment (ROI) 2.8 years
Item Per year
Sales price/ 3 kg packing RM 18.00
Total sales (packs) 50,000
C. Revenue RM 900,000
D. Gross Profit (C – B) RM 195,300
Use of basic oleochemicals and derived surfactants for efficient
performance
Formulated products to support the SMI
Shampoo for dyed hair
Anti-hair loss shampoo
Personal Care ProductsPersonal Care Products
Retsch Grinder
Roll Mill
Compact Powder Press
Item Main Company Contract manufacturing Company
A. Capital Investment:• Machinery & Equipment• Renovation• Vehicles • etc
�
�
�
�
�
RM 1,200,150
--�
�
RM 94,500
B. Operational Cost• Bas ic cosmetic raw material• Specialty cosmetic raw material• Labor• Utilities• Rental • Packaging• Marketing• etc.
�
�
�
�
�
�
�
�
�
RM 536,150
-�
�
�
�
--�
RM 93,404
Sales and RevenueItem Main Company Contract
manufacturing Company
Basic Cosmetic:Sales price/kgTotal sales (kg/year)Revenue (per year)
RM 1010,500 kgRM 105,000
Specialty Cosmetic:Sales price/unitTotal sales (Unit @ 30 g/year)Revenue (per year)
RM 4021,000 unitsRM 840,000
RM 403,000 unitsRM 120,000
C. Total Revenue RM 945,000 RM 120,000
D. Gross Profit (C – B) RM 408,850 RM 26,596
Economic Analysis Economic Analysis (Cosmetic Product: Basic & (Cosmetic Product: Basic &
Specialty)Specialty)
COST BENEFIT ANALYSIS Main Company Contract Manufacturing
Company
Internal Rate of Return (IRR) 35.09% 23.16%
Benefit : Cost RM 1.21 RM 1.02
Net Present Value @ 12% RM 1,163,459 RM 36,683
Return of Investment (ROI) 2.7 years RM 3.6 years
Emulsion systems using colloid technology to be formulated into agro products for efficient delivery of active
into plant.
� Herbicides, insecticides, fungisides, fertilizers and soil treatments� Adjuvants, surfactants for emulsifying,
dispersing, and foaming action for stable emulsion building
� Palm-based Adjuvant in Glyphosate Herbicides Formulation for Weed Control• Imaspro Biotech Sdn Bhd
� Palm-based Inerts in EW Insecticides Formulations for Pests Control• Ancom Crop Care Sdn Bhd
� Distributor : � Logistic/warehouse
� Trans portation� Packaging: 25 L, 4 L & 1 L
� Licensing : Pesticide Board of Malaysia & Manufacturer
To support the downstream activities of palm oil industries
Biodegradation Test Acute Toxicity TestAnalytical Services
For claims substantiation of consumer products
Efficacy tests ( in vivo and in vitro) for claims substantiation particularly for EU marketMicrobiology tes t
SPF claims
Skin color
Patch tes t for product safety
� Creates new job� New branding business� Opportunity for packaging industries� Creates market for local chemicals� Creates market for local consumer products� Abundance of raw material and plant based
resources � Higher profit margins
Acknowledgment:Datuk Dr Choo Yuen May (DG of MPOB), Dr Hazimah Abu Hassan (Director of AOTD), Pn Rosnah Ismail, Dr Yeong Shoot Kian, Pn Zulina Abd Maurad, En Zailan Abu Bakar, Pn Noor Azeerah Abas